Lecture 2 CAD/CAM branch third class

Terms and Definitions

ME 482 -Cutting
Metal Manufacturing Systems
Asst.Lec Mostafa Adel 1
 Metal cutting: material removal process using a sharp wedged tool
Various material removal processes
• Metal cutting –material removal by a sharp cutting tool, e.g., turning, milling,
drilling
• Abrasive processes –material removal by hard, abrasive particles, e.g., grinding
• Nontraditional processes - various energy forms other than sharp cutting tool to
remove material. Tool need not be harder than work is required.
Why Machining is Important
• Good dimensional accuracy and surface finish
• Fulfill functional requirements
• Improved performance of machined part
• Long service life of machined part
• Variety of part shapes and special geometry features possible, such as: Screw
threads, accurate round holes, very straight edges and surfaces
Disadvantages with Machining
• Wasteful of material
• Chips generated in machining are wasted material
• Time consuming or low material removal rate
• A machining operation generally takes more time to shape a given part than
alternative shaping processes, such as casting, powder metallurgy, or forming

ME 482 -Cutting
Metal Manufacturing Systems
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ME 482 -Cutting
Metal Manufacturing Systems
Asst.Lec Mostafa Adel 3
ME 482 -Cutting
Metal Manufacturing Systems
Asst.Lec Mostafa Adel 4
ME 482 -Cutting
Metal Manufacturing Systems
Asst.Lec Mostafa Adel 5
ME 482 -Cutting
Metal Manufacturing Systems
Asst.Lec Mostafa Adel 6
ME 482 -Cutting
Metal Manufacturing Systems
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ME 482 -Cutting
Metal Manufacturing Systems
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 N cut
1- 2.5=
volume/time

ME 482 -Cutting
Metal Manufacturing Systems
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 Types of Metal Cutting
Process

Orthogonal cutting is also known as two dimensional metal cutting in which the
cutting edge is normal to the work piece. (angle = 90deg)
Oblique cutting is also known as three dimensional cutting in which the cutting
action is inclined with the job by a certain angle called the inclination angle. (angle
≠ 90deg)

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0482 -Cutting
ME
Metal Manufacturing Systems
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 (a) Schematic illustration of cutting with an oblique tool.
(b) Top view, showing the inclination angle, i.
(c) Types of chips produced with different inclination
angles.

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Metal Manufacturing Systems
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 Orthogonal Cutting Oblique Cutting

ME 482 -Cutting
Metal Manufacturing Systems
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ME 482 -Cutting
Metal Manufacturing Systems
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Built-up-Edge (BUE) formation
• Causes of formation
• In machining ductile metals like steels with long chip-tool
contact length, lot of stress and temperature develops in the
secondary deformation zone at the chip-tool interface.
• Under such high stress and temperature in between two clean
surfaces of metals, strong bonding may locally take place due
to adhesion similar to welding.
• The welding starts forming as an embryo at the most favorable
location and thus gradually grows as schematically shown in
Fig.

ME 482 -Cutting
Metal Manufacturing Systems
Asst.Lec Mostafa Adel 14
Scheme of built-up-edge formation

ME 482 -Cutting
Metal Manufacturing Systems
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 • With the growth of the BUE, the force, F also gradually
increases due to wedging action of the tool tip .
• Whenever the force, F exceeds the bonding force of the
BUE, the BUE is broken or sheared off .

Characteristics of BUE
• Built-up-edges are characterized by its shape, size and
bond strength, which depend upon:
• work tool materials
• stress and temperature, i.e., cutting velocity and feed
• cutting fluid application cooling and lubrication.

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Metal Manufacturing Systems
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 Different forms of built-up-edge
• BUE may develop basically in three different shapes as
schematically shown in Fig.

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Metal Manufacturing Systems
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 Overgrowing and overflowing of BUE
causing surface roughness
• In machining too soft and ductile metals by tools like high
speed steel or uncoated carbide the BUE may grow larger and
overflow towards the finished surface through the flank as
shown in Fig.

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Metal Manufacturing Systems
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 • While the major part of the detached BUE goes away
along the flowing chip, a small part of the BUE may
remain stuck on the machined surface and spoils the
surface finish.
• BUE formation needs certain level of temperature at the
interface depending upon the mutual affinity of the work-
tool materials. With the increase in Vc and( so mean feed )
the cutting temperature rises and favoure BUE formation.
• But if VC is raised too high beyond certain limit, BUE
will be squashed out by the flowing chip before the BUE
grows.

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Metal Manufacturing Systems
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 Role of cutting velocity and feed on BUE formation

• Fig. up shows schematically the role of increasing VC

and so on BUE formation (size).

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Metal Manufacturing Systems
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 Effects of BUE formation
• Formation of BUE causes several harmful effects, such as:

• It unfavorably changes the rake angle at the tool tip causing increase in
cutting forces and power consumption
• Repeated formation and dislodgement of the BUE causes fluctuation in
cutting forces and thus induces vibration which is harmful for the
tool, job and the machine tool.
• Surface finish gets deteriorated
• May reduce tool life by accelerating tool-wear at its rake surface by
adhesion and flaking

• Occasionally, formation of thin flat type stable BUE may reduce tool
wear at the rake face.

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Metal Manufacturing Systems
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